Light display structures

ABSTRACT

Useful light display structures are configured so that they can be economically fabricated and assembled. The light display structures generally comprise a plurality of light-emitting elements that are coupled between first and second conductors with the addition of other structures (e.g., spacers, light redirectors, substrates, wire bonds, tabs, posts, ground planes and blocks) that support or augment the conductors.

CROSS REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.10/773,353 which was filed Feb. 5, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to light display structures andlighted commodities that include these structures.

2. Description of the Related Art

A variety of light display structures have been provided in response tothe advantageous features of light-emitting diodes (e.g., low voltage,low heating, low maintenance, color diversity and long life). Thesestructures, however, have generally been complex and expensive toproduce.

BRIEF SUMMARY OF THE INVENTION

Advantageous light display structure embodiments are formed withlight-emitting elements. The drawings and the following descriptionprovide an enabling disclosure and the appended claims particularlypoint out and distinctly claim disclosed subject matter and equivalentsthereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are top and side views of a light display structureembodiment of the present invention and FIG. 1C is an enlarged view ofanother embodiment for structure within the curved line 1C of FIG. 1B;

FIG. 2 is an enlarged isometric view of the light display structure ofFIGS. 1A and 1B that illustrates additional light display structureembodiments;

FIGS. 3A-3D are views along the plane 3-3 of FIG. 1B that illustrateadditional light display structure embodiments;

FIG. 4 is an isometric view of the light display structure of FIG. 3Cwhich emphasizes its flexible, elongate form;

FIGS. 5A and 5B are views of additional light display structures thatcan be carried on the structure of FIG. 4;

FIGS. 6A-6C are enlarged plan views of another light display structureembodiment;

FIGS. 7A and 7B are enlarged views along the plane 7-7 of FIG. 6B thatillustrate additional light display structure embodiments;

views along the plane 5-5 of FIG. 4B that illustrate additional lightdisplay structure embodiments;

FIG. 8 is an enlarged view similar to FIG. 6B that illustratesadditional light display structure embodiments;

FIG. 9 is an enlarged view along the plane 9-9 of FIG. 8 thatillustrates additional light display structure embodiments;

FIG. 10A is a top view of another light display structure embodimentembodiments;

FIG. 10B is a view along the plane 10B-10B of FIG. 10A;

FIG. 10C is a top view of another light display structure embodiment;

FIG. 10D is a view along the plane 10D-10D of FIG. 10C;

FIG. 11 is a plan view of another light display structure embodiment;

FIGS. 12A-12D are enlarged views of structural embodiments within thecurved line 12 of FIG. 11;

FIGS. 13A-13D are views that illustrate assembly of another lightdisplay structure embodiment;

FIG. 14A is a plan view of another light display structure embodiment;

FIG. 14B is a view along the plane 14B-14B in FIG. 14A;

FIG. 15A shows plan and side views of another light display structureembodiment;

FIG. 15B is an isometric view which shows the embodiment of FIG. 15Aarranged in an array of similar embodiments; and

FIGS. 16-21 show light display structure embodiments in association withdifferent articles of merchandise

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-21 illustrate advantageous light display structure embodimentsthat can be economically fabricated and assembled.

Attention is initially directed to FIGS. 1A and 1B which illustrate adisplay structure embodiment 20 for energizing at least onelight-emitting element 22. The structure includes first and secondspaced elongate conductors 24 and 25 and at least one support member inthe form of a spacer that is coupled and positioned to support thespaced conductors.

In particular and as indicated by a spacer 26A, the spacers each definean aperture 28 to receive the light-emitting element as it contacts thefirst and second conductors 24 and 25. The spacer 26A illustrates theaperture 28 while the spacer 26B illustrates reception of thelight-emitting element 22 into the aperture. Each spacer 26 also definesat least one light redirector 30 that is positioned to redirect lightaway from its respective light-emitting element 22.

In particular, the light redirector may be configured in any of variousforms (e.g., a reflective wall or a refractive wall) that will direct atleast a portion of the light away from the spacer. For simplicity, thelight redirector will subsequently be referred to as a wall which may beflat in one embodiment. In another embodiment, it preferably has aconcave shape as shown in FIG. 1A. In another embodiment, the wall mayhave a substantially parabolic shape to enhance redirection of thelight.

In the structure embodiment of FIGS. 1A and 1B, each spacer 26 definesfirst and second walls 32 and 33 that diverge with increasing distancefrom one side of their aperture 28 and third and fourth walls 34 and 35that diverge with increasing distance from another side of theiraperture 28. In one embodiment, the spacer may include a base 38 thatdefines the aperture 28 and the walls extend upward from the base.

As shown in FIG. 1B, the display structure may include a polymer (e.g.,a thermoplastic or a thermosetting polymer) insulator 40 that enclosesthe second conductor 25. In this case, the insulator preferably definesan opening 41 positioned to facilitate contact between thelight-emitting element and the second conductor 25. The spacers 22 arepositioned to space the first and second conductors apart locally whilethe insulator 40 insures they do not contact elsewhere.

Although the light display structures of the invention may carry variouslight-emitting elements, the structure 20 of FIGS. 1A and 1B isespecially suited to carry a light-emitting diode (LED) which isreceived in the aperture 28 with its cathode in contact with the secondconductor 25 and its anode in contact with the first conductor 24.

In operation of the light display structure 20, a voltage is appliedbetween the first and second conductors 24 and 25 which energizes theLED and causes light to be emitted from its light-emitting junction 44.As shown in FIG. 1A, the light radiates from the junction so that somelight rays 46 issue directly away from the spacer 26B and other lightrays 48 are redirected by the walls 32-34 to also radiate away from thespacer 26B.

As shown in FIG. 1C, another display structure may apply (e.g., byprinting, transfer printing, silkscreening) an insulator 50 on thesecond conductor 25. The insulator is arranged (e.g., by masking or byablating) to define a gap or aperture 52 into which the LED is received,i.e., the insulator 50 is configured to permit coupling of the LED tothe second conductor.

The enlarged isometric view 60 of FIG. 2 supplements FIGS. 1A and 1B. Itshows a strip 62 that facilitates fabrication of the spacers (26 inFIGS. 1A and 1B). The strip can be easily molded from a polymer and hasa base 38 that defines apertures 28 and walls 30 that extend upward fromthe base. For example, the walls may include the first and second walls32 and 33 that diverge with increasing distance from one side of theiraperture 28 and the third and fourth walls 34 and 35 that diverge withincreasing distance from another side of their aperture 28. Although notrequired, the diverging walls preferably abut at their ends that areproximate to their respective aperture. The walls terminate in a backwall 63 and a top wall 64.

A light-emitting element 22 in the form of an LED is shown in theprocess of being received into an aperture 28. Joining elements 65 and66 are preferably formed of conductive materials (e.g., conductiveepoxy, solder, reflow solder) and are provided to join the diode's anodeto the first conductor 24 and the diode's cathode to the secondconductor 25. This operation insures electrical continuity between thefirst and second conductors and their respective contacts of the LED.When a voltage is imposed between the conductors, the LED is energizedand light is radiated from the diode's junction 44 and at least aportion of that light is redirected latterly away from the conductors 24and 25 by the walls 30.

The strip 62 may be formed with a notch 68 that facilitates separationof one spacer from an adjoining spacer. As shown in FIG. 2, variousother strip embodiments may be formed. For example, the spacer structure70 defines two wall structures that face oppositely to be operative withapertures 28A and 28B. In an assembly process, spacers can be easilybroken from the strip 62 (with aid, for example, from the notch 68) andspaced along the first and second conductors as shown in FIGS. 1A and1B.

The first and second conductors 24 and 25 and their spacers 26 may beenclosed with various substantially-transparent structures to formelongate radiating elements. For example, FIG. 3A (a view along theplane 3-3 of FIG. 1B) shows them enclosed in a thermoplastic shrink tube80 and FIG. 3B shows them enclosed by a thermoplastic molded cover 82(the spacer's back wall 63 is indicated in each of these figures). InFIG. 3C, the cover 82 has been modified to a cover 84 that defines amounting surface 85 that can abut, for example, a floor or wall.

In FIG. 3D, the cover 82 of FIG. 3B has been modified to a cover 86 thatdefines a pair of protrusions 87 in addition to defining the mountingsurface 85 of FIG. 3C (the protrusions appear as outward-extending ribswhen envisioned in the elongate structure 90 of FIG. 4 which isdescribed below). Because of the flexible nature of these protrusions orribs, they flex and absorb the pressure of an impinging object (e.g., apedestrian's shoe) to thereby prevent damage to light-emitting elementswithin (as shown in FIG. 2).

In FIG. 3E, the cover 82 of FIG. 3B has been modified to a cover 88 thatdefines a mounting flange 89 which can facilitate attachment (e.g., withadhesive, with mechanical elements such as rivets or by sewing) tovarious objects (e.g., footwear, clothing apparel and architecturalmountings).

Structures such as those of FIGS. 3A-3E can be used to form elongatelight display structures such as the structure 90 of FIG. 4 which can bebent into various forms and which radiates light laterally when avoltage is placed across the first and second conductors 24 and 25.

Transparent or translucent decorative FIG. 92 can be molded in variousforms that slide onto (or snap over) the structure 90 as shown in FIG.5A. Alternatively, a decorative FIG. 94 can include a hinged member 95(a non-engaged position is shown in broken lines) which facilitates itsinstallation over the structure 90 as shown in FIG. 5B.

FIGS. 6A-6C illustrate another display structure embodiment 100 forcarrying at least one light-emitting element 22. As shown particularlyin FIG. 6A, a spacer 102 is shaped to define an array of apertures 22and also to define an array of cup-shaped walls 104 that each surround arespective one of the apertures. FIG. 6B shows an array oflight-emitting elements 22 that are each received in a respective one ofthe apertures. FIG. 6B also shows a plurality of first conductors 24that each contact a first side of a selected group of the light-emittingelements 22. These conductors are also shown in FIG. 7A which is anenlarged view along the plane 7-7 of FIG. 6B.

In particular, FIG. 7A shows the spacer 102 positioned to space thefirst and second conductors 24 and 25 with a light-emitting elementreceived in an aperture to contact the first and second conductors. Thesecond conductor 25 may comprise a plurality of elongate conductors(similar to the first conductors 24 in FIG. 6B) or may comprise aconductive sheet that contacts all of the light-emitting elements ofFIG. 6B.

In one light display embodiment, the light-emitting elements are LEDswhich radiate light from their light-emitting junctions 44. When avoltage is placed across the first and second conductors, the LEDs areenergized and light rays 106 are radiated from the junction 44 andredirected laterally from the plane of the spacer 102 by the cup-shapedwall 104 as shown in FIG. 7A.

The first conductors 24 of FIG. 6B are shown to have a linear form butthis is one of many possible embodiments. FIG. 6C, for example, shows afirst elongate conductor 24A which is configured to contact variousselected light-emitting elements that do not lie along a linear path.These elements can be selected so that the radiated light forms variousfigures (e.g., a letter, a number or a word) frofm the array oflight-emitting elements.

The cup-shaped wall 104 of FIG. 7A is shown to have a concave shapewhich may be substantially parabolic to enhance the redirectedradiation. FIG. 7B is similar to FIG. 7A with like elements indicated bylike reference numbers. Similar to the spacer 102 of FIG. 7A, a spacer110 is positioned to space the first and second conductors and itdefines an array of apertures to each receive a respective one of thelight-emitting elements 22 as it contacts respective ones of the firstand second conductors.

In contrast to the spacer 102, however, the spacer 110 defines acup-shaped wall 112 that has a flat shape rather than the concave shapeof the wall 104 of FIG. 7A. Also the spacer 110 spaces the first andsecond conductors apart without completely filling the space betweenthese conductors. Instead, the spacer 110 comprises a sheet that isformed to define the cup-shaped wall 112 and to contact the secondconductor 25 locally and contact the first conductor 24 in otherregions.

FIG. 8 illustrates another light-emitting structure 120 which is similarto the structure 100 of FIG. 6B with like elements indicated by likereference numbers. The structure 120, however, includes asubstantially-transparent sheet 122 formed of a suitable polymer (e.g.,mylar). The first conductors 24 can be bonded to the sheet 122 and thesheet is then placed to bring these conductors into contact with theirrespective light-emitting elements 22.

As shown in FIG. 9 (a view along the plane 9-9 of FIG. 8), the sheet 122and its first conductors 24 may be locally shaped to form dimples 124that enhance contact between the conductors and their respectivelight-emitting elements 22. In another light-emitting structureembodiment, the sheet 124 may carry photoluminescent films 126 (e.g.,phosphor films, conjugated polymer, organic phosphor). In operation ofthis embodiment, light rays 128 from the light-emitting element 22 areredirected by the cup-shaped wall (104 in FIG. 8) to strike the phosphorfilms. In response to this excitation, the luminescent films emit lightrays 130. Different luminescent films may be used to selectively displaydifferent colors.

Semiconductor LEDs have been configured to emit light with a variety ofwavelengths and, generally, the forward voltage drop of these LEDsincreases as the wavelength decreases. For example, red, yellow andgreen LEDs typically exhibit forward voltage drops in the respectiveranges of 1.8-2.0 volts, 2.0-2.2 volts and 2.2-2.5 volts. In addition,each LED typically has a specified forward current that is recommendedto enhance LED performance parameters (e.g., intensity, dissipation andlifetime).

Accordingly, it may be desirable to insert a resistive member betweenthe LEDs of the light display structures and their associated first andsecond conductors. This is exemplified in FIG. 2 where a resistivemember 136 (e.g., a resistive film such as a thin film resistor, a thickfilm resistor, conductive paste, conductive epoxy) is inserted betweenthe anode of the LED 22 and the first conductor 24 (the insertion isindicated by insertion arrow 138—e.g., the member can be carried overthe anode). Alternatively, the resistive member may be inserted betweenthe cathode of the LED 22 and the second conductor 25.

The resistivity and cross section of the resistive member 136 areconfigured to realize a predetermined resistance which will provide thespecified forward current when a selected supply voltage is applied viathe first and second conductors 24 and 25. An exemplary green LED, forexample, is specified to have a forward voltage drop of 2.8 volts and aforward current of 20 milliamps. For this particular LED, theresistivity and cross section of the resistive member 136 wouldpreferably be configured to provide a resistance that increases throughthe range of 10 to 100 ohms when the selected supply voltage increasesthrough the range of 3.0 to 4.8 volts.

In general, the resistivity and cross section of the resistive member136 are chosen to realize the specified forward current in response to aprovided supply voltage. To enhance conductivity between elements,conductive films may be carried on the anode and cathode surfaces andalso inserted between the resistive member and its associated one of thefirst and second conductors.

FIGS. 10A-10D illustrate other light display embodiments of the presentinvention. In particular, FIG. 10 A shows a light display embodiment 140in which the first and second conductors 24 and 25 are arranged (e.g.,side by side) to facilitate the insertion of wire bonds 142 that couplea selected one of the anode and cathode surfaces (wherein the anodesurface has been selected in FIG. 10A) of LEDs 22 to the first conductor24.

As shown in FIG. 10B, a resistive member 136 (introduced in FIG. 2) ispreferably inserted between the LED 22 and the wire bond 142. Inaddition, the LED's anode and cathode (and the resistive member 136) maybe joined to the wire bond 136 and the second conductor 25 withconductive elements 65 and 66 (also introduced in FIG. 2).

FIG. 10C illustrates a light display embodiment 160 that is similar tothe embodiment 140 of FIG. 10A with like elements indicated by likereference numbers. In this embodiment, however, the first conductor 24is modified to a conductor 164 which defines a plurality of tabs 166.Each of the LEDs 22 is then coupled between the second conductor 25 anda respective one of the tabs 166. FIG. 10D is similar to FIG. 10B exceptthat the conductor 164 and its tab 166 is substituted for the firstconductor 24 and the wire bond 142.

The light display embodiments of FIGS. 10A-10D may also be enclosed withvarious substantially-transparent structures to form elongate radiatingelements. In FIGS. 3A-3D, for example, they can be substituted for thelight display embodiments of FIGS. 1A-1C and 2 (which are represented inFIGS. 3A-3D by first and second conductors 24 and 25 and a spacer's backwall 63).

The light display structure embodiments shown in FIGS. 1-10D are simpleand comprise few parts so that they can be economically fabricated fromvarious polymers and quickly assembled. They lend themselves forrealization in a variety of forms. For example, they can be realized inelongate display structures wherein light is directed laterally from theelongate shape or sheet-like display structures wherein light isdirected laterally from the sheet. The descriptions of these embodimentsinclude walls which are light redirectors that may be configured invarious forms (e.g., reflective or refractive walls).

The spacers (e.g., 26, 102) shown in various ones of the figures, theinsulator 40 of FIG. 1B, the tube 80 of FIG. 3A, the cover 82 of FIG. 3Band the transparent sheet 122 of FIGS. 8 and 9 can be fabricated fromvarious insulators such as polymers (e.g., polyimide and mylar). Thefirst and second conductors (24 and 25 in FIG. 2) may be formed fromvarious conductive metal foils (e.g., copper and silver). The spacersmay also be fabricated in colors that enhance the light redirected fromtheir respective LEDs.

In an exemplary display embodiment, the photoluminescent films 126 ofFIG. 9 may include conjugate polymers and organic phosphors that areexcited, for example, by blue LEDs to thereby cause the redirected lightrays 130 to be substantially white.

FIG. 11 illustrates another light display structure in the form of aflexible light wire 200 which can provide an extensive set of lightsource embodiments 202 that are spaced along a substrate 204 which ispreferably formed from a flexible material (e.g., a polymer). FIG. 12Ais an enlarged view of the area 12 in FIG. 11 and FIG. 12B is asectioned side view of the structure of FIG. 12A. These figures showthat an embodiment 202A of the light source is formed with the aid ofapertures 205 in the substrate 204. Received within each aperture is alight-emitting element which, in this embodiment, is an LED 206 that hasa light-emitting junction 44 defined by abutted upper and lowerelectrodes 207 and 208 (a more general designation of the structurespreviously referred to as anode and cathode).

To facilitate energization of the light source 202A, first and secondconductors 211 and 212 are respectively dispensed along the upper andlower surfaces of the substrate 204 with the first conductor contactingthe upper electrode 207 and the second conductor 212 contacting thelower electrode 208. In one forming embodiment, this may be quicklyaccomplished with conventional wire bonding processes and equipment. Forexample, the first conductor 211 can be rapidly dispensed along thesubstrate 204 to a point adjacent the aperture 205.

A first bond 221 is then formed at the substrate adjacent the aperture205 after which the first conductor continues to be dispensed. A secondbond 222 is then formed and attached to the upper electrode 207 afterwhich the first conductor continues to be dispensed. A third bond 223 isthen formed and attached to the substrate adjacent the aperture.

Having formed and attached the first, second and third bonds, the firstconductor is subsequently pulled down to the next aperture and the wirebonding process continued. A similar wire bonding process is used torapidly install the second conductor 212 to the substrate 204 and thelower electrode 208. Each LED will then be energized when a voltagepotential is placed across the first and second conductors.

Various wire bonding processes may be used (e.g., the bonds 221, 222 and223 may be balls formed by melting of gold wire or may be wedge contactsformed with ultrasonic processes). In other embodiments of the first andsecond conductors 211 and 21-2, segments of these conductors may beprinted-circuit paths formed with conventional printed circuitprocesses. In one embodiment, for example, only those segments of thefirst conductor 211 of FIGS. 12A and 12B between the bonds 221 and 223are formed with wire bonding processes and the other segments of thefirst conductor are formed with printed circuit processes. The secondconductor can be formed with a similar combination of processes.

FIGS. 12C and 12D show another light source embodiment 202B that issimilar to the light source 202A of FIGS. 12A and 12B with like elementsindicated by like reference numbers. In contrast, however, a portion 225of the upper electrode 207 is broken away to expose a portion of thelower electrode 208. This permits the second conductor 212 to be movedfrom its location in FIG. 12B (i.e., adjacent the lower substratesurface) to join the first conductor 211 adjacent the upper substratesurface. In FIG. 12C, accordingly, the second conductor 212 is now wirebonded to the upper substrate surface and to the exposed portion of thelower electrode 208.

From FIGS. 11-12D, it is thus apparent that the structures of the lightwires 202A and 202B facilitate a rapid, economical fabrication process.Once fabricated and installed, an energy source (e.g., battery) can beplaced across the first and second conductors 211 and 212 tosimultaneously energize each LED 206 along the light wire so that itemits light 226 as shown in FIGS. 12B and 12D. The substrate 204 may beformed of a variety of materials such as a laminated film or an extrudedpolymer (e.g., thermoplastic or thermosetting polymer). Flexibility ofthe substrate will enhance the flexibility of the light wire 200 of FIG.11.

The light wire 200 can be environmentally protected with an appliedovercoat 228 formed, for example, of heat-shrinkable tubing, a polymersleeve or a conformal coat. Prior to the overcoat, each LED 206 can besurrounded by a protective coat 229 of a substantially transparentmaterial (e.g., epoxy). This coat may be configured with an index ofrefraction that enhances emission of the light 226. The coat and theovercoat are especially suitable if the LEDs have not been passivated.

In another light source embodiment, a resistive member 230 (similar toresistive member 136 introduced with respect to FIG. 2) is inserted inFIG. 12B between a second bond 222 and the upper electrode 207 of theLED 206 as indicated by insertion arrow 232. The resistive memberfacilitates control of the emitted light 226. As previously disclosed,for example, it facilitates control over the forward voltage drop and/orthe forward current of the LED to thereby alter and enhance theappearance of the emitted light 226.

In another light source embodiment, the resistive member may be insertedbetween the lower electrode 208 of the LED and its respective bond.Alternatively, resistive members can be inserted to abut each of theupper and lower electrodes. In other light source embodiments, resistivemembers may be inserted in similar manners in the light sourceembodiment of FIGS. 12C and 12D. In these latter embodiments, theresistive members will abut the upper electrode and/or the exposedportion 208 of the lower electrode.

It is noted that FIGS. 12B and 12D show the LED 206 and the substrate204 to have substantially-similar heights or thicknesses. In other lightdisplay embodiments, however, they may differ. For example, thethickness of the substrate 204 may be reduced so that the LED junction44 is above the substrate which may enhance emission of the light 226.

FIGS. 13A-13D illustrate another light display structure in the form ofa light bulb 240 (shown in 3 orthogonal views in FIG. 13D) which isformed with a light wire 242 that provides a set of light sources 202Cthat are spaced along a polymer substrate 244 (shown, for example, inFIG. 13A). The polymer substrate 244 is similar in composition to thepolymer substrate 204 in FIG. 11 but its form differs as it has across-like shape which includes legs 245 that couple to a longer leg246. A first conductor 211 runs through some of the light sources 202Cand is coupled to an orthogonal conductor 247 which runs through theother light sources 202C.

FIG. 13B illustrates an elongate metallic heat sink 250 in associationwith the light wire 242. This figure shows the legs 245 and the longerleg 246 in a fabrication process wherein they are being bent so thatthey can each run down a respective side of the heat sink 250. As shownin FIG. 13C, this process has been continued until each of the legs(e.g., the legs 245) are in contact with the sides of the heat sink 250.

The light source 202C is similar to the light source 202A of FIG. 12Awith like elements indicated by like reference numbers. In contrast tothe light source 202A, however, the light source 202C lacks the secondconductor 212 of the light source 202B. Instead, the heat sink 247 abutsthe electrode 208 of the LED to serve as an electrical connection tothis electrode and to also provide a conduction path which transportsheat away from the light sources 202C.

The first conductor 211 can be installed with a wire bonding processsimilar to that introduced with reference to FIG. 12A. For example, FIG.13C shows first, second and third bonds 221, 222 and 223 that can besuccessively installed to secure the first conductor respectively to oneof the substrate legs 245, the upper electrode 207 and another of thesubstrate legs 245.

When the light wire 242 and heat sink 250 are assembled together, theyare then received within the globe 260 and base 261 of the light bulb240 of FIG. 13D. In this arrangement, the conductor 211 is electricallyconnected to one of the base 261 and the bulb terminal 262 (that issurrounded by the base) and the heat sink 250 is electrically connectedto the other. A voltage across the base and terminal is communicated viathe first conductor 211 and the heat sink 250 to energize the LED ineach of the light sources 202C. In response, each of the LEDs radiatesthe light 226 shown in FIG. 13C. The lifetime of the LEDs issubstantially enhanced because heat is rapidly carried away from themalong the conduction path provided by the heat sink 250.

FIGS. 14A and 14B illustrate another light display structure in the formof a segmented display 270 which is formed with light wires 271 thateach provides a plurality of light sources 202D. The display is formedwith first conductors 211, a substrate 271, and a plurality ofelectrically conductive ground planes 272. The substrate defines aplurality of apertures 205 and each of a plurality of LEDs 206 isreceived within a respective one of the apertures.

Each of the ground planes 272 abuts the back of the substrate 271 and isin contact with lower electrodes of a respective set 273 of the LEDs206. That is, the LEDs are grouped in sets 273 and each of the groundplanes contacts lower electrodes of LEDs in its respective one of thesets. Each ground plane is associated with a respective one of switches274 that can selectively couple that ground plane to a voltage potential(e.g., ground). Each light source 202D is similar to the light source202C of FIG. 13C except that the substrate, 245 is replaced with thesubstrate 271 and the heat sink 250 is replaced by a ground plane 272.

In FIG. 14A, the first conductors 211 bear the designations of A throughG. As shown, each of these conductors can be wire bonded to thesubstrate 271 and wire bonded to the upper electrode of a respective LEDin each of the sets 273. In each set, the LEDs are arranged as segmentsof a number. The conductor labeled A is wire bonded to the upper LED 206in each of the sets 273, the conductor labeled B is wire bonded to anupper left LED 207 in each of the sets 273 and so on for the rest of theconductors 211.

In a first operational phase of the segmented display 270, the switch274 of one of the ground planes 272 is closed to couple that groundplane to a first voltage potential (e.g., ground). At this time, all ofthe other switches 274 are open. A second voltage potential is placedupon a first selected group of the conductors A-G to thereby energize aselected group of the LEDs 206 of the ground plane whose switch 274 isclosed. LEDs in the other sets 273 will not be energized because theirrespective switches 274 are open. Accordingly, a selected number isdisplayed by the LEDs associated with the closed switch.

In a second operational phase of the segmented display 270, the switch274 of a different one of the ground planes 272 is closed and theremainder of the other switches 274 are open. The second voltagepotential is placed upon a second selected group of the conductors A-G.The second selected group of conductors is not necessarily the same asthe first selected group. Accordingly, the selected number that isdisplayed by the LEDs associated with the closed switch is notnecessarily the same as the earlier displayed number.

Additional operational phases are conducted for each of the remainingground planes after which the entire process is rapidly repeated.Although each of these operational phases is quite brief (e.g., afraction of a second), each displayed number will appear to becontinuous because of the rapid repetition and the retinal retention oflight in the human eye.

In another light display embodiment, the substrate 271 is formed of aflexible polymer and the ground planes 272 is formed of flexible andelectrically conductive material to enhance flexibility of the segmenteddisplay 270. Such embodiments are useful in applications in which it isdesired to conform the display to a curved surface.

FIG. 14B is a view along the plane 14B-14B of FIG. 14A. This sectionalview shows one of the ground planes 272 abutting the back of thesubstrate 271 and one of the LEDs 206 within an aperture 205. In anotherlight display embodiment, the surface 272S of the ground plane 272 isconfigured with a reflective surface that provides a high degree ofreflection while maintaining electrical conductivity. The reflectivesurface may, for example, be realized with a color (e.g., white) and/ora finish (e.g., gloss finish) that enhances light reflection. Thisreflective ground plane enhances the intensity of the emitted light 226of the LED 206.

In another light display embodiment, a reflective member 275 is insertedbetween the ground plane 272 and the LED 206 as indicated by insertionarrow 276. The reflective member is configured as described above inorder to reflectively enhance the emitted light 226.

As further shown in FIG. 14B, each LED 206 may be covered with alight-enhancing member 279. In one embodiment, this light-enhancingmember may be a substantially transparent material (e.g., epoxy) thathas an index of refraction that enhances the emitted light 226. Inanother embodiment, the light-enhancing member may be a holographicmember that alters and enhances the appearance of the emitted light 226.For example, the holographic member may any of various polymers whosesurface has been configured to diffuse light in manners that achieve aholographic effect. In each of the sets 273 of LEDs, these holographicmembers may be oriented in different directions to obtain differentholographic effects in the LEDs of that set.

FIG. 15A illustrates side and front views of another light displaystructure in the form of an array member 280 which is formed with firstconductors 211, a substrate 282, a conductive block 283 and a pluralityof insulated metallic pins 284. The block 283 contacts the lower surfaceof the substrate 282 and the lower electrode of each of LEDs 206 thatare received in the apertures 205 of the substrate 282. The insulatedpins 284 extend through the substrate and the block so that they areaccessible at each side of the combined substrate and block.

Each first conductor 211 can be installed with a wire bonding processsimilar to that introduced with reference to FIG. 12A. For example, thefirst, second and third bonds of FIG. 12A can be used in a similarmanner to successively secure a first conductor 211 to one of the pins284, the upper surface of the substrate 282, and to the upper electrodeof a corresponding one of the LEDS 206. Light sources 202E are thusformed which are each similar to the light source 202C of FIG. 13Dexcept that the substrate 244 is replaced with the substrate 282 and theheat sink 250 is replaced by the conductive block 283.

In operation of the array member 280, a first potential is applied tothe block 283 and a second potential is applied to a selected one of thepins 284. Accordingly, a selected one of the LEDs 206 is energized. In adisplay embodiment, each of the LEDs is associated with a phosphor filmwhich causes its emitted light to have a selected color. For example,the LEDs in FIG. 15A are indicated with letters R, G and B indicatingthat they emit red, green and blue light when the second potential isapplied to their respective ones of the pins 284. Because green light isgenerally not as intense as the other colors, two of the LEDs arestructured to emit green light as they are simultaneously energized.

The structure of the array member 280 of FIG. 15A is particularly suitedfor use in a light display array 290 that is shown in FIG. 15B. Thearray is formed by arranging a plurality of the array members 280 in anarray relationship which is indicated by broken lines 292. Although onlyone array member 280 is shown in FIG. 15B, each of the spaces defined bythe broken lines 292 would be filled with a respective one of the arraymembers.

Because of the structure shown in FIG. 15A, the array members 280 can betightly arranged in FIG. 15B with their pins 284 each available at therear of the array and they're LEDs forming a lighted array at the frontof the array. Heat from the LEDs is quickly carried away by theconduction path formed by the blocks 283. Various light patterns can bedisplayed by placing potentials on selected ones of the pins 284. Theblocks 283 may be formed from any material (e.g., a metal) that iselectrically and thermally conductive.

Other embodiments of the array member 280 are formed by those whichinclude a reflective back member 294 which is inserted (as exemplifiedby insertion arrow 295) between the block 283 and its LEDs 206 tothereby redirect any light that emits from the back sides of the LEDs.The reflection substantially enhances the light intensity visible to aviewer of the array member. Although shown having a size similar to thatof the substrate 282, there may, for example, be smaller back films thatare each inserted between the block 283 and a respective one of theLEDs.

Another array member embodiment includes an opaque overlay 296 which ispositioned (as indicated by positioning arrow 297) over the substrate282. The overlay defines apertures similar to the apertures 205 of thesubstrate 282 and these apertures are positioned to each pass lightemitted from respective one of the LEDs 206. Various overlay embodimentsmay be formed with masking processes (e.g., silk screening or the use ofdecals). The overlay 296 is configured to enhance the appearance of thearray member.

Yet another array member embodiment includes epoxy coatings 298 (one isindicated by a broken-line ellipse) that are positioned over each LED206. Each coating may include light dispersing particles formed ofreflective material (e.g., titanium oxide and silver) so that itdisperses the light emitted from its respective LED. This embodimentparticularly enhances the appearance of the array member.

In still another array member embodiment, the broken-line ellipse 298represents a holographic lens which is positioned proximate to the LEDs206 to further enhance the appearance of the array member 280.

It is noted that various structures have been described above in FIGS.12A-15B to enhance emitted light of LEDs. These include substantiallytransparent material (e.g., epoxy) configured with a selected index ofrefraction, substantially transparent material configured with lightdispersing particles formed of reflective material (e.g., titanium oxideand silver), phosphor films which cause the emitted light to have aselected color, and holographic members whose surface has beenconfigured to diffuse light in manners that achieve holographic effects.These light-enhancing structures may be used in conjunction with (e.g.,disposed proximate to) any of the light display embodiments describedabove.

Light display embodiments of the invention are particularly suited forcombination with articles of merchandise (i.e., goods which may beoffered for sale) to form commodities (i.e., economic goods, articles ofcommerce) such as the lighted commodity embodiments illustrated in FIGS.16-21. In general, the light display structures shown in these lightedcommodity embodiments may be formed with light display structureembodiments exemplified by those illustrated in FIGS. 1-15A. Althoughthe lighted commodities are shown in the form of exemplary objects(e.g., a Christmas tree), they may generally be arranged in any desiredgraphic or textual form.

FIG. 16, for example, shows a lighted commodity embodiment 300 that isparticularly suited for forming lighted signs. It includes a panel 302and light display structures 303 and 304 carried on the panel. Thedisplay structures are formed with first and second conductors (22 and24 in FIG. 1A), spacers (26 in FIG. 1A) and light-emitting elements (22in FIG. 1A). For simplicity of illustration, the first and secondconductors of the display structure 303 are shown as a single line, thespacers are not explicitly shown and the light-emitting elements areindicated as dots with light rays radiating therefrom. The displaystructure 304 is only indicated by broken lines to indicate that it isnot currently selected. In an important feature of the invention, thedisplay structures are nearly invisible when not illuminated.

In an exemplary form, the display structure 303 is shaped to spell theword “open” and the display structure 304 is shaped to spell the word“closed”. The letters of these words are preferably formed by a singledisplay structure but, for clarity of illustration, the conductorsbetween letters are not shown. In an exemplary use of the commodity 300,a power source (e.g., a battery or a permanent power source) would beswitched to illuminate, at different times, a selected one of thedisplay structures 303 and 304 to indicate the present status ofsomething associated with the sign (e.g., a business).

The panel 304 is preferably formed from any of a variety of translucentplastics (e.g., acrylic) which will receive and spread a portion of thelight emitted by the display structures 303 and 304 to thereby present apleasing effect to the lighted sign. To further enhance the lightedsign, the commodity 300 may include a reflecting sheet 306 (e.g., awhite sheet of paper, plastic or other thin material) positioned on oneside of the panel 300 to thereby spread and redirect emitted light backthrough the panel.

FIG. 17 is a view along the plane 17-17 in FIG. 16 which shows anothercommodity embodiment in which an edge of the panel 302 is shaped todefine a channel 307 which receives another display structure 308. Thechannel 307 and display structure 308 may run along a portion of or allof the perimeter of the panel 302. The channel can be shaped in forms(e.g., a parabola) that facilitate passage of emitted light through thepanel 302 to thereby further enhance the appearance of the lighted sign.In addition, a reflective sheet 309 (similar to the reflective sheet306) may be positioned to cover the groove and further redirect lightthrough the panel. Although the reflective sheets 306 and 309 areslightly spaced from the panel 302 in FIGS. 16 and 17 to betterdelineate them, they would generally abut the panel.

Another lighted commodity embodiment is shown with front, side and backviews of the lighted sign 310 of FIG. 18. This sign includes a panel 311and a message 312 that is carried on either the front side 314 of thepanel or on the back side 315. Similar to the panel 304 of FIG. 16, thepanel 311 may be formed from any of a variety of translucent plastics(e.g., acrylic) which will receive and spread a portion of the lightemitted by a light display structure 316 which is preferably carried onthe back side 315.

Although the message 312 is indicated by an exemplary text “message”, itmay be in the form of any message structure such as text, graphics orcombinations of text and graphics. Although the message is shown on thefront side 314, it may be carried on the back side 315 in otherembodiments.

The light from the light display structure 316 is spread throughout thepanel 311 and enhances the appearance of the message 312. Accordingly,this light display structure is arranged in a form (e.g., the serpentineform of FIG. 18) that effectively illuminates the panel 311. A diffusingsheet 318 may be inserted between the panel 311 and the displaystructure 316 to diffuse the structure's light and further enhance theappearance of the lighted commodity 310.

Another lighted commodity embodiment 320 is shown in FIG. 19 to be ashoe 322 and a light display structure that is carried on the shoe. Forexample, the shoe includes a tongue 323 and a light display structure324 that is carried on the tongue. For another example, the shoe has abody 325 and a light display structure 326 that is carried on the body.It is noted that the laces of the shoe 322 are schematically shown overthe tongue and on the body.

The tongue 323 and its associated display structure 324 may be removablycoupled to the body 325 with first and second fasteners 321 (e.g.,engagable snaps) to facilitate its replacement with another tongue thatcarries a different display structure. The fasteners may also be part offirst and second electrical paths associated with a battery 328 thatpowers the display structure 324. A switch 329 (e.g., apressure-activated switch) may be inserted between the battery and thedisplay structure to provide a means of activating (i.e., energizing)the display (e.g., by interrupting at least one of the electricalpaths).

In FIG. 19, another light display structure 330 is carried on aremovable body portion 332. In particular, the example arrow 334 isassociated with a portion of the boundary between the body 325 and thebody portion 332 and indicates that this portion can be removablycoupled to the body with a fastener in the form of a zipper 334. Thisfastener facilitates the replacement of this body portion with anotherbody portion that carries a different display structure.

FIG. 20 illustrates another lighted commodity embodiment 340 which isformed with a clothing item 342 (in particular, a T shirt) and a lightdisplay structure 344 that is carried on the clothing item.

Another lighted commodity embodiment 350 is shown in FIG. 21 to beformed with a container 342 (in particular, a bottle) and a lightdisplay structure 344 that is carried on the container.

As disclosed above, various light display structure embodiments includeconductors having path segments formed with wire bonding processes. Itis to be understood that, in other embodiments of these light displaystructures, some or all conductor path segments may be formed with wirebonding processes and some or all conductor path segments may be formedwith printed circuit processes. An exemplary example was disclosed inwhich those path segments of the first conductor 211 of FIGS. 12A and12B between the bonds 221 and 223 are formed with wire bonding processesand the other path segments of the first conductor are formed withprinted circuit processes.

Although not explicitly shown in all of the lighted commodityembodiments of FIGS. 16-21, their light display structures may beactivated with a battery (e.g., the battery 328 of FIG. 19) and thisactivation may be accomplished with a switch (e.g., the switch 329 ofFIG. 19). Alternatively, they may be activated with other power sources(e.g., permanent power sources) that are spaced away from the lightedcommodity embodiments.

The embodiments of the invention described herein are exemplary andnumerous modifications, variations and rearrangements can be readilyenvisioned to achieve substantially equivalent results, all of which areintended to be embraced within the spirit and scope of the appendedclaims

1. A display structure, comprising: a substrate that has first andsecond substrate sides and defines a plurality of apertures thatcommunicate with said first and second substrate sides; a plurality oflight-emitting diodes that each have a semiconductor junction betweenabutted first and second electrodes and that are each received within arespective one of said apertures wherein a portion of said firstelectrode is absent to thereby provide access to an exposed portion ofsaid second electrode; a first conductor that is coupled to said firstsubstrate side and coupled to the first electrode of each of saiddiodes; and a second conductor that is coupled to said first substrateside and coupled to the exposed portion of each of said diodes; saiddiodes thereby energized by a potential between said first and secondconductors.
 2. The structure of claim 1, wherein said first and secondconductors are wire bonded to said first electrode and said exposedportion respectively.
 3. The structure of claim 2, wherein said firstand second conductors are wire bonded to said first substrate side. 4.The structure of claim 1, further including, proximate to each of saiddiodes, a light-enhancing structure that is a selected one of a materialwith a selected index of refraction, a material configured with lightdispersing particles, a material configured to diffuse light in aholographic effect, and a phosphor film.
 5. A display structure,comprising: a substrate that has first and second substrate sides anddefines a plurality of apertures that communicate with said first andsecond substrate sides; a plurality of light-emitting diodes that eachhave a semiconductor junction between abutted first and secondelectrodes and that are each received within a respective one of saidapertures; a first conductor that is coupled to said first substrateside and coupled to the first electrode of each of said diodes; and asecond conductor that is coupled to said second substrate side andcoupled to the second electrode of each of said diodes; said diodesthereby energized by a potential between said first and secondconductors.
 6. The structure of claim 5, wherein said first and secondconductors are wire bonded to said first and second electrodes.
 7. Thestructure of claim 6, wherein said first and second conductors are wirebonded to said first and second substrate sides respectively.
 8. Thestructure of claim 5, further including, proximate to each of saiddiodes, a light-enhancing structure that is a selected one of a materialwith a selected index of refraction, a material configured with lightdispersing particles, a material configured to diffuse light in aholographic effect, and a phosphor film.
 9. A display structure,comprising: a substrate that has first and second substrate sides anddefines a plurality of apertures that communicate with said first andsecond substrate sides; a plurality of light-emitting diodes that eachhave a semiconductor junction between abutted first and secondelectrodes and that are each received within a respective one of saidapertures; a conductor that is coupled to said first substrate side andcoupled to the first electrode of at least one of said diodes; and anelectrically-conductive member that contacts the second electrode of atleast one of said diodes; said diodes thereby energized by a potentialbetween said conductor and said member.
 10. The structure of claim 9,wherein said member is a post, said substrate is wrapped about a portionof said post with said second substrate side contacting said post andsaid post contacts the second electrode of all of said diodes, andfurther including: a terminal in contact with one of said conductor andsaid post; a cylindrical base surrounding said terminal and in contactwith the other of said conductor and said post; and a glass globeextending from said base and surrounding said substrate and said diodes;said diodes thereby energized by a potential between said terminal andsaid base.
 11. The structure of claim 9, wherein: said member is one ofa plurality of ground planes that are positioned adjacent said secondsubstrate side; each of said ground planes contacts the secondelectrodes of a corresponding set of said diodes wherein said set isarranged as segments of a number; and said conductor is one of aplurality of wires that are each coupled to the first electrode of arespective diode of each of said sets.
 12. The structure of claim 11,further including a plurality of switches that are each arranged tocouple a potential to a respective one of said ground planes.
 13. Thestructure of claim 9, further including a plurality of insulated pinswherein: said member is an electrically conductive block that contactssaid second substrate side; each of said pins extends through saidblock; and said conductor is one of a plurality of wires that are eachcoupled to the first electrode of a respective one of said diodes andcoupled to a respective one of said pins.
 14. The structure of claim 13,further including: phosphor films that are each carried over arespective one of said first electrodes to selectively display differentcolors; and an opaque overlay positioned over said substrate withapertures arranged to correspond to respective ones of said diodes. 15.The structure of claim 9, further including, proximate to each of saiddiodes, a light-enhancing structure that is a selected one of a materialwith a selected index of refraction, a material configured with lightdispersing particles, a material configured to diffuse light in aholographic effect, and a phosphor film.
 16. The structure of claim 9,further including an article of merchandise wherein said conductor andsaid member are flexible wires and said substrate is a flexible polymersubstrate that is carried by said article.
 17. The structure of claim16, wherein said substrate defines at least one light redirectorpositioned to redirect light from a respective one of said diodes. 18.The structure of claim 16, wherein said article is a selected one of asign, a container, a clothing item, a shoe, a tongue of a shoe
 19. Thestructure of claim 16, further including at least one fastener thatremovably couples said substrate to said article.
 20. The structure ofclaim 19, wherein said fastener is a zipper.